CN108407413A - 实木膜及适用所述实木膜的实木注塑物制造方法 - Google Patents

实木膜及适用所述实木膜的实木注塑物制造方法 Download PDF

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CN108407413A
CN108407413A CN201710561604.7A CN201710561604A CN108407413A CN 108407413 A CN108407413 A CN 108407413A CN 201710561604 A CN201710561604 A CN 201710561604A CN 108407413 A CN108407413 A CN 108407413A
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solid wood
wood
line
film
layer
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金槿河
崔静娥
金成勋
朴喜大
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Three Fu Precision Chemical Co Ltd
Intops Co Ltd
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Three Fu Precision Chemical Co Ltd
Intops Co Ltd
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Abstract

本发明提供一种实木膜及适用所述实木膜的实木注塑物制造方法，所述实木膜包括：纹木；无纺布，其利用非水系的粘合剂接合于所述纹木的下面，从而保护纹木不受水分的影响；成形改善层，其接合于所述无纺布的下面，防止因施加至纹木的热而导致纹木起褶皱，或者发生破裂；以及热塑性粘合层，其接合于所述成形改善层的下面，实现与注塑树脂的接合，能够在保持实木的触感及外观的同时，改善耐湿/耐光可依赖性及成形性，从而完美实现实木的触感及外观。

Description

实木膜及适用所述实木膜的实木注塑物制造方法
技术领域
本发明涉及一种实木膜及适用所述实木膜的实木注塑物制造方法(Real woodfilm and Method of manufacturing an injection molded product using the realwood film)，更为详细地，涉及一种实木膜及适用所述实木膜的实木注塑物制造方法，所述实木膜能够防止由水分导致的纹木的变形，即使在热压(Heat Press)成形后也能够完好地保持形态，并且比通常纹木柔韧(flexible)，同时即使施加热和压力也不会发生纹木的变形，从而大幅改善成形性。
背景技术
通常，为了给予精致美和高级感，使得车辆内装部件(门饰板(door trim)、齿轮箱(gear box)、缓冲垫(crash pad)、仪表盘、中央仪表板(center fascia panel)等)的材质不同，并且趋势为为了使得消费者的感性得到满足，在车辆的制造厂正在使用不同种类的内装部件，例如，具备天然纹木层的内装部件的使用增加并成为趋势，所述天然纹木层的高级感和美感极佳。
现在，将塑料(plastic)树脂注塑成形从而制作相当于内装部件的主体的基底，将树纹样的膜纸浮在转移溶液并进行转移(transfer)处理，使得经过转移处理的膜纸结合于所述基底的一个侧面后，按照适合于所述基底的形状对所述膜纸进行切割及修整(trimming)加工，从而制造用于车辆的内装部件。
此外，为了使得经过转移处理的膜纸中有害成分最少化，要经过清洗(washing)工艺和干燥(drying)工艺，由此，也有制造工艺数增多和生产性低下的问题。
又另外的现有的内装部件通过如下方式制造：将塑料树脂注塑成形从而制作相当于内装部件的主体的基材，将2个纹木和1个铝板加工制作为薄板形态，将所述纹木和铝板放入模具，以规定温度和压力进行加压，以便成为铝板插入所述纹木之间的状态，从而制作所述纹木和铝板结合为一体的天然纹木层，对所述天然纹木层的表面进行涂敷(coating)处理，使得经过涂敷处理的所述天然纹木层结合于所述基底的一个侧表面后，按照适合于所述基底的形状对所述天然纹木层进行切割及修整(trimming)加工。
但是，所述的制造方法是使得制作天然纹木层的工艺和在所述天然纹木层的表面进行涂敷处理的工艺在一个装备上进行的，为此需要高价的装备，由此，有增加制造成本的问题。
此外，层叠于纹木之间的铝板是为了确保天然纹木层的刚性而使用的，但是，内装部件的形状上有曲面或者曲折的部位时，因所述铝板而导致很难将天然纹木层制作为想要的曲面或曲折的形状，由此，制作完成的内装部件也有产品的质量下降的问题。
观察用于克服所述问题的现有的技术，登记专利第10-1192271号(2012.10.11)提供了用于车辆的天然木材纹木内装部件制造方法，所述用于车辆的天然木材纹木内装部件制造方法包括如下过程：利用刀(knife)将具有湿气的天然木材切削为0.1mm至1mm的厚度，然后用蒸气蒸从而获得纹木木材纸；所述纹木木材纸重叠许多张，通过上板和下板对所述木材纸进行挤压成形，从而获得具有木材的图案(pattern)和纹路的天然木材纹木图案层，所述上板和下板在相互面对的面凸出形成有凸起；将所述天然木材纹木图案层投入于注塑模具后，在所述天然木材纹木图案层的后面将树脂向后方注塑从而形成树脂层；以及通过利用所述注塑模具进行的注塑过程，在后方注塑所述树脂的天然木材纹木图案层的前面涂敷透明保护层。
但是，就纹木而言，很容易因水分而膨胀、收缩，同时发生变形，若发生纹木变形，则有如下问题：纹木有随着纹理产生褶皱或木眼凸出的倾向，所以外观上不光滑、不美丽，从而无法生产优质的产品。
发明内容
本发明的目的在于提供一种实木膜及适用所述实木膜的实木注塑物制造方法，所述实木膜为了使得由水分导致的变形最小化，将非水系的粘合剂适用于附着于纹木下面的无纺布，从而防止纹木变形或者收缩，同时防止起皱的现象；包括成形改善层，以便即使热压成形(pre-forming)后也能够完好地保持形态，从而能够在保持实木的触感及外观的同时，改善耐湿/耐光可靠性及成形性，进而完美实现实木的触感及外观。
根据本发明的实木膜包括：纹木；无纺布，其利用非水系的粘合剂接合于所述纹木的下面，从而保护纹木不受水分的影响；成形改善层，其接合于所述无纺布的下面，防止因施加至纹木的热而导致纹木起褶皱，或者发生破裂；热塑性粘合层，其接合于所述成形改善层的下面，实现与注塑树脂(resin)的接合。
此时，优选地，根据本发明的非水系的粘合剂，其将无纺布接合于所述纹木，并通过按照相应比率配合酯(ester)类和醚(ether)类来形成所述非水系的粘合剂。
并且，优选地，根据本发明的所述成形改善层由PC、PET、PETG、ABS、PMMA、PI、PEN中任意一个的材质组成。
此外，选择性地将热熔粘接剂(hot melt)分别层叠于根据本发明的所述纹木、无纺布、成形改善层、热塑性粘合层之间，从而实现层间接合。
同时，根据本发明的实木注塑物制造方法包括如下步骤：a)准备实木膜；b)通过热压工艺形成(forming)所述实木膜；c)将成形完成的实木膜收容于注塑模具后，向实木膜背面注入树脂；以及d)从注塑模具取得向背面注塑树脂的实木膜后，向所述实木膜表面实施涂装，从而形成保护层。
此时，根据本发明的所述保护层涂敷于所述纹木的上面，从而保护纹木表面不受紫外线影响。
根据本发明的实木膜及适用所述实木膜的实木注塑物制造方法具有如下效果。
为了使得由水分导致的变形最小化，将非水系的粘合剂适用于附着于纹木下面的无纺布，从而防止纹木变形或者收缩，同时防止起皱的现象，包括成形改善层，以便即使热压成形(pre-forming)后也能够完好地保持形态，从而能够在保持实木的触感及外观的同时，改善耐湿/耐光可靠性及成形性，进而完美实现实木的触感及外观。
附图说明
图1是示出根据本发明的一个实施例的实木膜的截面的截面图。
图2是示出适用根据本发明的实施例的实木膜的实木注塑物的截面的截面图。
图3是示出根据本发明的其他实施例的实木膜的截面的截面图。
图4是按步骤对适用根据本发明的实施例的实木膜的实木注塑物制造方法进行示出的框图。
具体实施方式
以下，参照附图对根据本发明的优选实施例进行详细地说明。在此之前，本说明书以及权利要求书中使用的术语或词汇并非限定解释为通常的或字典上的意思，发明者为了以最好的方法来说明其自己的发明，基于能够恰当地定义术语的概念的原则，仅应解释为符合本发明的技术思想的意思和概念。
据此，由于在记载于本说明书的实施例和附图中示出的构成只不过是本发明的最优选的实施例，并非全部代表本发明的技术思想，因此应理解为在本申请当时会有可代替它们的均等的变形例。
本发明涉及一种实木膜及适用所述实木膜的实木注塑物制造方法，其能够防止由水分导致的纹木的变形，即使在热压成形后也能够完好地保持形态，并且比通常纹木柔韧(flexible)，同时即使施加热和压力也不会发生纹木的变形，从而大幅改善成形性，以下，参照附图进行观察。
根据本发明的实木膜100包括纹木10、无纺布20、成形改善层30及热塑性粘合层40，首先所述纹木10是想要表现木材的质感，将天然木材切削为厚度0.1mm至1mm而形成的，经常使用在想要表现木材固有的纹路及特性的装饰材料。
所述纹木10与一般的纹木一样，因此省略其详细的说明。
并且，就根据本发明的实木膜100而言，将无纺布20利用非水系的粘合剂接合于所述纹木10的下面，所述纹木10很容易因通过表面浸透的水分而膨胀、收缩，同时发生变形，若在所述纹木10发生变形，则随着纹理产生褶皱或木眼凸出，外观上不光滑、不美丽。
所述无纺布20防止由所述水分导致的纹木10的变形，所述无纺布20利用非水系类型(type)的粘合剂接合于所述纹木的下面，从而防止由于水分而导致纹木10变形或收缩起皱的现象。
此时，对所述无纺布20进行接合的非水系的粘合剂，是将酯(ester)类聚氨酯(urethane)粘合剂及即使在水分中粘合力也不降低的材料的醚(ether)类聚氨酯(urethane)粘合剂按照最佳比率进行配合的。
在此，在所述无纺布20只使用酯(ester)类粘合剂的情况，粘合力优秀，但因加水分解而导致水分浸透时纹木和粘合力会降低，从而适用不发生加水分解反应的成分的醚(ether)类粘合剂，从而即使水分浸透时也不会发生纹木10和无纺布20间的粘合力降低。
在此，按照酯(ester)类/醚(ether)类的不同比率，通过下面的【表1】及【表2】可确认耐湿可靠性。
【表1】
耐湿可靠性(组成及热特性、粘合)
观察所述【表1】，看测试(Test)结果时，导出如下结果：单独适用聚酯多元醇(Polyester polyol)的NASA-A粘合力最优秀，但越使用聚醚多元醇(Polyether polyol)粘合力越低。
并且，通过将所述样品(sample)粘合而制成的试样对加水分解性进行评价，通过【表2】观察，最适合的配合如下所示。
【表2】
耐湿可靠性(组合及加水分解测试)
此时，将粘合的试样在-80℃温度、90％湿度的烤箱中保管一周、两周后，对试样进行粘合测试，测试结果可以确认即使只放入聚酯(Polyester)25％左右，加水分解性也会变好，粘合力也没有大幅降低。
据此，就根据本发明的实木膜100而言，将无纺布20浸渍在按照酯类75：醚类25的比率进行配合而形成的粘合剂后，将充分地涂敷粘合剂的所述无纺布20接合于纹木10的下面，从而防止由水分导致的纹木10变形或收缩的现象。
并且，将成形改善层30接合于所述无纺布20的下面，所述成形改善层30在所述纹木10热压成形时，防止由热变形导致的纹木10起褶皱或者发生破裂。
此时，优选地，所述成形改善层30由PC(聚碳酸酯，Polycarbonate)、PET(聚对苯二甲酸乙二醇酯，Polyethylene terephthalate)、PETG(聚对苯二甲酸乙二醇酯-1,4-环己烷二甲醇酯，polyethylene terephthalate glycl-modified)、ABS(丙烯腈－丁二烯－苯乙烯共聚物，acrylonitrile-butadiene-styrene)、PMMA(聚甲基丙烯酸甲酯，poly(methylmethacrylate))、PI(聚酰亚胺，Polyimide)、PEN(聚萘二甲酸乙二酯，Polyethylene naphthalate)中任意一个的材质组成。
在此，在本发明中以PET(聚对苯二甲酸乙二醇酯，Polyethylene terephthalate)为基准，按照不同厚度对成形性进行试验，如下面【表3】所示。
【表3】
从所述结果可知，75um、100um的PET层显示出良好的结果，优选地，为了稳定性而适用100um厚度。
此外，将热塑性粘合层40接合于所述成形改善层30的下面，所述热塑性粘合层40实现与注塑树脂的接合，其材质适用二异氰酸酯(DIISOCYANATES)类、长链二醇(多元醇)(LONG-CHAIN DIOLS(POLYOL))类、扩链剂(CHAIN EXTENDERS)类，在二异氰酸酯(DIISOCYANATES)类中由二苯甲烷二异氰酸盐(MDI，Diphenylmethane Diisocyanate)、甲苯二异氰酸酯(TDI，Tolune Diisocyanate)、六亚甲基二异氰酸酯(HexamethyleneDiisocyanate)、异佛尔酮二异氰酸酯(IPDI，Isophorone Diisocyanateiisocyanate)、氢化苯基甲烷二异氰酸酯(H12MDI，Dicyclohexylmethane-4，4’-Diisocyanate)中任意一个组成，在长链二醇(多元醇)(LONG-CHAIN DIOLS(POLYOL))类中由聚四亚甲基醚二醇(PTMEG，Polytetramethylene ether glycol)、聚氧化丙烯二醇(PPG，Polyoxypropyleneglycol)、聚乙二醇(PEG，Polyoxyethylene glycol)中任意一个组成，在扩链剂(CHAINEXTENDERS)类中由1，4-丁二醇(1,4-Butanediol)组成。
同时，就根据本发明的实木膜100而言，如图3所示，就所述纹木10、无纺布20、成形改善层30、热塑性粘合层40而言，选择性地将热熔粘接剂60层叠于所述纹木10、无纺布20、成形改善层30、热塑性粘合层40之间，使得所述热熔粘接剂60通过高温进行熔融，从而使得所述纹木10、无纺布20、成形改善层30、热塑性粘合层40能够相互接合。
此时，所述热熔粘接剂60全部层叠于所述纹木10和无纺布20之间、所述无纺布20和成形改善层30之间、所述成形改善层30和热塑性粘合层40之间，并通过高温得到熔融，从而能够实施层间接合剂的功能，但又并非限定于此，也可以只层叠于所述纹木10和无纺布20之间、所述无纺布20和成形改善层30之间、所述成形改善层30和热塑性粘合层40之间中任意一个地方。
此外，就根据所述本发明的实木膜100而言，在其表面上对载体膜(carrier film)50进行点焊，并对纹木10的上面进行整理，从而防止实木膜的成形工艺中纹木的损伤。
对适用根据本发明的实木膜100的注塑物制造方法进行观察，如下。
首先，在a)步骤中，准备实木膜100(S100)。
此时，准备的实木膜100包括：纹木10，其厚度为0.2mm～0.5mm；无纺布20，其通过非水系的粘合剂接合于所述纹木10的下面，保护纹木10不受水分的影响；成形改善层30，其接合于所述无纺布20的下面，防止纹木10因施加于所述纹木10的热而起褶皱，或者发生破裂；以及热塑性粘合层40，其接合于所述成形改善层30的下面，实现与注塑树脂的接合。
此外，就根据本发明的实木膜100而言，可将载体膜50点焊于其表面上。
并且，在b)步骤中，利用热压工艺形成通过所述a)步骤(S100)的实施而准备的所述实木膜(S110)。
此时，将所述实木膜100收容于向着上、下或前、后啮合的冲压模具内部后，施加相应温度150℃～250℃的热，同时实施10秒左右热压(heat pressing)，从而使得所述实木膜100以具有曲折面的形式形成为相应形状。
并且，在c)步骤中，将在所述b)步骤(S110)成形完成的实木膜100收容于注塑模具后，向实木膜背面注塑树脂(S120)。
此时，将去除载体膜50的所述实木膜100收容于向着上、下或前、后啮合的注塑模具内部后，向所述实木膜100的背面，即换句话说，所述实木膜100的热塑性粘合层40层叠的面注塑树脂80。
并且，在d)步骤中，在所述c)步骤(S120)从注塑模具取得向背面注塑树脂80的实木膜100后，向所述实木膜100表面实施涂装，从而形成保护层70(S130)。
此时，涂敷于所述纹木10的上面的保护层70保护纹木10表面不受紫外线影响。
本发明以示出于附图的实施例作为参考进行了说明，但应理解为，这只不过是例示的，若是本技术领域的具有一般知识的技术人员，则能够由此进行多种变形及均等的其他实施例。据此，本发明的真正的技术性保护范围应由所附的权利要求书的技术思想决定。
标号说明
10:纹木
20:无纺布
30:成形改善层
40:热塑性粘合层
50:载体膜
60:热熔粘接剂
70:保护层
80:树脂

Claims (7)

1.一种实木膜，其包括：
纹木；
无纺布，其利用非水系的粘合剂接合于所述纹木的下面，从而保护纹木不受水分的影响；
成形改善层，其接合于所述无纺布的下面，防止因施加至纹木的热而导致纹木起褶皱，或者发生破裂；以及
热塑性粘合层，其接合于所述成形改善层的下面，实现与注塑树脂的接合。
2.根据权利要求1所述的实木膜，其特征在于，
将无纺布接合于所述纹木的非水系的粘合剂，是由酯类和醚类配合而形成的。
3.根据权利要求2所述的实木膜，其特征在于，
将所述酯类和醚类混合而形成的非水系的粘合剂，是按照酯类75：醚类25的比率进行配合的。
4.根据权利要求1所述的实木膜，其特征在于，
所述成形改善层由PC、PET、PETG、ABS、PMMA、PI、PEN中任意一个的材质组成。
5.根据权利要求1所述的实木膜，其特征在于，
还选择性地将热熔粘接剂分别层叠于所述纹木、无纺布、成形改善层、热塑性粘合层之间。
6.一种实木注塑物制造方法，其包括如下步骤：
a)准备根据权利要求1所述的实木膜；
b)通过热压工艺形成所述实木膜；
c)将成形完成的实木膜收容于注塑模具后，向实木膜背面注塑树脂；以及
d)从注塑模具取得向背面注塑树脂的实木膜后，向所述实木膜表面实施涂装，从而形成保护层。
7.根据权利要求6所述的实木注塑物制造方法，
所述保护层涂敷于所述纹木的上面，从而保护纹木表面不受紫外线影响。
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